Insulator bracket and method of making the same



Feb.

14, 1933. c. FAsslNGER 1,897,385

INSULATOR BRACKET AND METHOD OF MAKING THE SAME Filed Aug. 4, 19:50 5 sheets-sheet' 1 Feb. l14, 1933. Q FASSlNGER 1,897,385

INSULATOR BRACKET AND METHOD OF MAKING THE SAME Filed Aug. 4, 195o l:s sheets-shew 2 v 1 lINVENTOR @www Mffi Feb. 14, 1933. c. FAsslNGI-:R 1,897,385

INSULATOR BRACKET AND METHOD OF MAKING THE SAME Filed Aug. 4, 1930 5 Sheets-Sheet 5 j .....Iaa'n C. FASSINGER Feb. 14, 1933.

INSULATOR BRACKET AND METHOD OF MAKING THE SAME Filed Aug. 4, 1930 5 Sheets-Sheet 4 R O T N E V m C. FASSINGER Peb. 14, 1933.

INSULATOR BRACKET AND METHOD OF MAKING THE SAME Filed Aug. 4, 1950 5 Sheets-Sheet 5 VPatented Feb. 14, 1933 UNITED STATES PATENT oFFl'cE CHARLES FASSINGER, OF PITTSBURGH, PENNSYLVANIA, ASSIGNOR TO OLIVER IRON &

STEEL CORPORATION, OF PITTSBURGH, PENNSYLVANIA, A CORPORATION. OF PENN- Uil SYLVANIA INSULATOR BRACKET AN D. METHOD OF MAKING THE SAME Application led August 4, 1930. Serial No. 473,117.

This invention relates to an insulator bracket and the method of manufacturing the same, and particularly to that type of bracket which'is known in the pole line hard ware industry as a secondary rack.

Insulator brackets of this general type ar extensively used, and as commonly constructed, they comprise a base member having a .plurality of horizontally projecting arms thereon. These arms have a hole through the outer end thereof. A single pin passing through a lined hole in the several horizontal arms supports a series of insulators.

As heretofore constructed it has been common practice in the art to form the base of rolled sheet metal and to form the horizontal arms by forging, or by shaping specially rolled structural shapes.

According to the present invention there 1s provided an insulator rack which may be formed entirely of flat sheet metal, resulting in a considerable economy in the manufacture of the rack. vAt the same time the rack has ample strength. The invention may be readily understood byy reference to the accompanying drawings in which:

lFigure 1l is a side elevation of a completed 30. insulator rack made in accordance with my Y Figure 4L is a plan view of the base before the arms have been placed thereon;

Figure 5 shows one of the sheet metal blanks from which the arm is formed;

Figure 6 is a longitudinal vertical section through the bed of a press specially constructed for making the assembly7 the parts showing the finishing step in the manufacture of the bracket, the view being in the plane of line VI-VI of Fig. 10; K

Figure 7 is a view similar to Fig. 6 showing the first step in uniting the arm to the base and forming the arm, the view beinga section in the plane of line VII-VII of Fig. 9;

Figure Sis a view similar to Fig. 7 showing the arm bent-to shape andthe relation of the parts ustY before the final operation shownin Fig. 6 is effected; i

Figure 9 's top plan View of the bed 0f the machine when the partsare in the position shown in Fig. 7, the base of the insulator Y derstood, however', that the invention is not limited to the employment of a particular machine. The machine as herein shown and described constitutes the subject matter of my copending application Serial No.' 473,681 filed August 7, 1930.

The construction of the insulator and the general steps in the manufacture thereof arek best described in connection ywith Figsl to 5 `of the drawings. The insulator rack comprises a base'2 which is preferably formed by pressing'a flat sheet of metal. .The'base comprises a central rib'V or channel portion 3 with lateralflanges t along each side of the base ofthe rib. Extending outwardly from the base at substantially right angles thereto are av plurality of arms 5 which are formed of sheet metal. These arms, as disclosed in Fig. 3, have an outer end portion 6 in which is a hole 7 Between the outer end portion 6 and the base are integral downwardly turned flanges 8 which reinforce the arm and impart rigidity thereto. The ends of the flanges 8 are drawn tightly against theV outer surface of the channel portion 3 of the base, the point of contact between the downwardly turned flanges and the base being marked 9.

In the manufacture of the base transverse slots l0 are formed therein. Each of theY arms. 5 has an inner end portion 11 which passes through the slot 10 and which is tightly riveted over on the underside of the chan` is clearly shown in Fig. 3, and which serves to vreinforce the arm against shearing strains at this point. Y

The arm 5 is formed from the blank shown inFig. 5. vThis blank is stamped out from flat sheet metal. In Fig. 5 the' blank itself is designated 13. On its inner end it has a central tongue 14, and on each side of the centra-l portion of the bla-nk are laterally extending tapered wings 15. The dotted lines in Fig. 5 indicate the lines alongwhich the metal blank is folded tol form the wings 15 into thereinforcing flanges 8 previously described. "Atthe Vouter end ofthe blank is the hole 7, previously described, andw'nich; is punched out when the blanky 13- is originally stamped from flat sheet metal. i It will be notfA ed by reference to'Fig. 5 that the end edges of the wings 15 Vare cut at a slightangle, as

'shown by the lines 16,'instead of being at right anglesl to the longitudinalaxis of the blank. v i

In the process of assemblingv'the insulator, the base 2 isfshaped up vfrom the flat sheet metal previously stamped to y size Yand the blanks 13 are stamped out of flat sheet. Each blank 13 may be heated to a bright red heat throughout substantially its ventire length, with Vthe exception that the outer end portion should be keptrelativelycold. When .thus

. heated the tongue 14V of the'blank is Yinserted through one offthe openingslO in the base member 2, the flangesl are folded down to formthe reinforcingy flanges 8,'and after this bending' operation yandfvvhile, the metal `is still hot the end portion 14 is ysubjected to an upsetting operation. Although I'khavey specied heating the blanks 13'as a stepin the above described operation, such step may be omitted. and the .operation carried out with thev blanks co ld. A This upsetting operation formsthe head portion 11 and the thickened or upset part 12. In theupsetting operation the arm 5 isrigidly held against downward movement while the base member 2 is rela-v tivelyfree'.l The exertionv vof an enormous pressure against the projectingend portion 14 of the blank not only'upse'tsthismetal, but forces the base down into tight engagement with the ends of thewings 8. The arm is thusv clamped to the baseso tightly that looseness cannot subsequently develop. n During this upsetting operation the angular ledges 16of the blank, after being bent down as shown in Fig. y2, arepressed so tightly against thejmetal of the base as to Contact with the base entirely along thek edge 9,"the operationjserving to more effectivelyclampV the two pieces together.

'InFigs 7 to 10, inclusive, Ihave shown the method by which the blank 13 `is Vbentto shape and riveted to the base member 2. This may be described by reference to the machine which I have illustrated Yfor effecting this process. The machine comprises a bed 20 having a laterally Vreciprocating head 21 which moves toward iand away from 4a stationary die block 22. The die block 22, as clearly shown in Fig. 9, has a substantially U-shapedrecess 23 therein. In front of this recess or groove at each side thereof are vertical shoulders 24. Secured to the front of the die block in spaced relation to these shoulders are keeper plates 25.

On the reciprocating head 21 is acooperatingdie member`26'which is moved by reciprocatio'n `ofthe head 21 from the position shown on the forward end thereof the diameter of which is approximately the same as the di- 'ameterofthe hole 7 blank 13.

f As shown in'Figs. 6, 7 and 8, the machine:` is provided with a plunger 29 which recipro-v cates vertically over 'the centerofthe die 22 andthe operationl of which isv corelated to the operation' of the reciprocating head2l as described lin my' copending: applic-ation above-mentioned. On the lower end of the plunger 29 isj afdie surface 30.

After the blank 13 has -been heated as previ'- ouslydescribed, itis set in thel guideway atk the front of the notch. 23 formed by the shoul-`r ders 24 andthe keeper plates 25. In Figs.V 7 and 9 the flat blank 13 is shown'set in the vdie.

inthe. way it is placed while hot. :Inthis position the lower end of theblankrests on: a shoulder 31 at the bottom of the die. .The

in the outer end of the blank'2 is then Vset on topfofthe" die 22 and the reciprocating v-head 21. in such manner thatthe projection 14 on the blank extends:

through one ofthe openings 10 in the base.

end ofthe die 26 next presses against the centralvportion ofthe blank. forcing it back into the'cavity or Yrecess 23. Since the cavity orA Vnotch 23 is of less width than the width of the blank'the wing portions 15 of the blank are bent around `into the substantiall'ywU- shape 'shown in Fig. 10. In Figs. 9 and A10 I have not shown the basei platej2, but it` is' i shownin Figs. 6to 8, inclusive.'

' When the die 26 forces the blank 13 back into the notch23 the tongue` 14 on the blank `projecting Vthroughjthe 4base plate 2 offthe bracket causes the bracket toy slide tothe right. This is-clearly shown in Figsjf and end of the base member 2 in Fig. 8 is a considerable distance to the right of the position shown in Fig. 7. When the die 26 completes its movement to the right the parts are in the position shown in Fig. 8 and the tongue 14 on the blank is directly under the vertically movable upsetting plunger 29. While the parts are held in this position the plunger 29 is forced down, upsetting the projecting tongue 14 and even upsetting the portion of the metal which passes through the slot 10 in the blank 2. As a matter of fact, the pressure is so heavy that the size of the opening 10 is actually expanded.

Since the blank is firmly held aga-inst vertical movement by reason of being confined in the die and by reason of the pin 28 passing through the hole 7 in the blank, the action in this operation is to cause the web of metal forming the rib 3 of the base to be firmly clamped between the riveted head of the projection 14 and the ends of the bent wings 15. As an additional feature to prevent any rela.- tive movement of the blank during the upsetting operation, the end of the die 26 is preferably provided with serrations or beads or teeth 26a which bite into the hot blank while the blank is confined in the notch 23 in the die. After the extension 14e has been riveted over the plunger 29 rises and the head 21 recedes. The spring-actuated kick-out bar 32 then acts to force the blank, which is firmly attached to the base plate 2, out of the recess in the die.

The base plate 2 is then lifted and another blank inserted in place at the front of the die 22. The base plate is then put back into position, but this time the tongue 14 of the second blank will project through the second opening 10 in the base plate. It will be noted that a clearance channel 33 is provided in back of the die block 22 to accommodate those arms which have been rigidly attached to the base plate.

The entire operation of inserting the heated blank and completing its shaping and at taching it to the base plate requires but a few seconds, so that the operation can be carried on with considerable rapidity.

The base member 2 if formed from flat sheet metal can be bent to shape and punched in a single operation, as will be readily understood to those skilled in the art. In place of using flat sheet metal the base member 2 may be formed of rolled stock, in which case the only operation required is the punching of the slots 10, and the forming of the holes 2a and 2". The holes 2a accommodate screws or bolts by mea-ns of which the fixture is secured to a pole or other structure on which it is to be mounted, while the holes 2b are provided primarily for reducing the Weight of the article.

As a modification of the process it is of course apparent that the fiat blank 13 can be bent to the shape shown in Fig. 10 before the tongue 14C is inserted through the hole 10 in the base' plate. c

The invention provides a bracket for iX- tures of this kind which is satisfactorily formed of sheet metal and which is rigidly secured to the base member in such manner that it cannot become detached under ordinary conditions of usage.

|The method provides for cutting the blank 13 from Hat sheet metal whereby a simple type -of punching or stamping machine can be employed. The bending over of the wings or reinforcing arms 8 is accomplished in the same heating that the riveting is accomplished, the riveting operation being done at almost the instant the bending operation is finished. A

lVhile I havev shown and described a particular formof anl insulator rack and the l in the operation and construction ofthe mechanism within the 'contemplation of my invention andunder the scope of the following claims.

I claim:

1. An article ofthe class described comprising a one-piece base plate having a sheetmetal supporting arm secured thereto, said sheet metal arm having integral flanges thereon the ends of which bear against one face of the base plate, the middle portion of the arm having an extension thereon passing through an opening in the base plate, the inner end of the extension being riveted over whereby the base plate is rigidly clamped between the ends of said flanges and the riveted end of the extension.

2. The method of forming a sheet metal arm and attaching it to a one-piece base plate ict to form a device of the class described, which comprises forming a blank from a piece of flat sheet metal, which blank has a hole at one end thereof and a tongue in the other end, heating the blank, inserting the tongue through an opening in the base plate adapted to receive it, thereafter folding the side portionsl of the blank inwardly to form flanges the ends of which extend over the baseplate, and then applying pressure to the projecting end of the tongue of the blank to upset the metal and rivet it over, the blank being supported against endwise movement during the upsetting operation, the means which bend the flanges inwardly being utilized to clamp the blank and hold it against endwise movement during the upsetting operation.

3. The method of forming an article of the class described having a one-piece base plat-e and an arm secured to the base plate projecting therefrom, which comprises forming the base plate with a hole therein, forming a nio ian

35, channel with side flanges thereon, a pluralitj7 flat sheet metal blank having a tongue projecting from one end thereof, heating` the blank, inserting the tongue through the hole in the base plate, bending the sides of the blank over to form flangesthe inner ends of which contact with the base plate, thennpy setting the tongue to rivet it over and clamp the base platebetween the endsof the flanges and the riveted 4over head. v

4. An insulator rack comprising a onepiece base plate formed in the shape of a channel with side flanges; thereon and having a sheet metal arm secured to the top sideY ofthe channel of said base plate, said arm having an extension passing through the top side of the channel and Vwhich is upset on the under face of the plate, said arm also having Y flanges thereon, the ends` of Vwhich bear against the outer face of thebase plate.

5.*An insulator'rack comprising a one-v piece base plate formed in the shape ofa channel with side flanges thereon, a YpluralityT of sheet metal arms secured to the top side of the channel of saidbase plate, said arms being formed of an integral piece of sheet metal having downwardly turned side flanges, the ends of which bear against the plates, the middle portion of each arm having an extension.V thereon which passes throuvhfan o enmv in the base )late the eX- tension being riveted over on the opposite face of the base plate.

Y 6. An insulator rack comprisingk a onepiece base plate formed in the shape of a of sheet metal arms secured to the top side of the channel of said base plate, said arms being formed of an integral piece of sheet metal having downwardly turned side flanges, the ends of which bear against the plates, the middle portion of each arm having an extension thereonl which passes through an opening in the base plate of larger cross-sectional area than the extensionrof the arm, the extension beingriveted over. onY

the opposite face of the base plate.

7. The method of forming an article of the class described having a one-pieceY base plate projecting therefrom, which comprises forming the base plate with a hole therein,

forming a flat sheet metal blank having a tongue projecting from one end thereof, said tongue being of smaller cross-sectional area than the hole in the base plate, heating the blank, inserting the tongue through the hole` in the base-plate, bending the sides of the blank over to form flanges, the inner ends of whichfcontactwith the base plate, then upsetting the tongue to rivet it over and clamp the base plate between the ends of the flanges and the riveted-over head.

In testimony whereof I have hereunto set y my hand.

Y cras.Y FASSI'NGER. 

